🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XL1200C

Year:

2009

Product Name:

Harley Davidson Sportster XL1200C 2009 Service Repair Manual

Platform Code:

XL

Engine Family Code:

Evolution (V-Twin)

👋 Introduction

Motorcycle Segment:

Cruiser motorcycle, known for its iconic styling and V-twin engine.

Target Audience:

Harley-Davidson owners, DIY enthusiasts, independent repair shops specializing in Harley-Davidson motorcycles.

Competitors 2009:

Other 1200cc cruiser motorcycles from brands like Indian, Victory, and some Japanese manufacturers (e.g., Honda Shadow, Yamaha V-Star, Kawasaki Vulcan).

Vehicle Features:

Custom styling, chrome accents, comfortable riding position, characteristic V-twin rumble, and extensive customization options.

Manual Value Proposition:

Provides the essential technical knowledge to maintain, repair, and troubleshoot the Sportster XL1200C, enabling cost savings and ensuring longevity.

📋 Manual Details

Main Coverage:

Repair and overhaul of Harley-Davidson Sportster XL1200C 2009

Assumed Technician Skill:

Fully conversant with general automobile procedures

Estimated Pages:

Approximately 500-700 pages (typical for comprehensive service manuals of this era)

Type:

Service Manual / Workshop Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete disassembly, assembly, inspection, and repair of the Evolution 1200cc V-Twin engine, including cylinder heads, pistons, crankshaft, connecting rods, camshafts, and valve train.

Fuel System:

Fuel injection (EFI) system diagnosis and repair, fuel pump, injectors, throttle body, sensors (MAP, IAT, TPS), and evaporative emissions system.

Ignition System:

Ignition module, coil, spark plugs, and related wiring.

Transmission:

5-speed constant mesh transmission overhaul, gear inspection, clutch service (primary and clutch pack), and transmission fluid specifications.

Drivetrain:

Primary drive chain inspection and adjustment, clutch operation, and belt drive system maintenance.

Brakes:

Front and rear brake system diagnostics, caliper overhaul, brake pad replacement, master cylinder service, hydraulic system bleeding, and fluid specifications.

Suspension:

Front fork (39mm) disassembly, seal replacement, oil specifications, and rear shock absorber service and replacement.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator), starter motor, lighting (headlight, tail light, turn signals), instrumentation, and fuses/relays.

Chassis And Frame:

Frame inspection, steering head bearing service, wheel bearings, and swingarm pivot inspection.

Bodywork And Trim:

Fender removal and installation, fuel tank removal and mounting, seat servicing, and handlebar components.

Preventive Maintenance:

Oil changes, filter replacement, spark plug replacement, chain lubrication and adjustment, tire pressure checks, brake fluid checks, and general inspection procedures.

Troubleshooting:

Diagnostic procedures for common issues related to engine performance, electrical systems, fuel delivery, and braking.

Repair Overhaul:

Step-by-step instructions for the disassembly, cleaning, inspection, repair, and reassembly of all major mechanical and electrical components.

Diagnostics:

Diagnostic Trouble Codes (DTCs) and their interpretation, use of diagnostic tools, and symptom-based troubleshooting guides.

Torque Specifications:

Detailed torque values for all fasteners and critical components.

Wiring Diagrams:

Comprehensive electrical schematics with component identification and wire routing.

Depth Level:

Comprehensive; covers everything from basic maintenance to complete engine and transmission rebuilds.

Special Tools:

Identification of necessary Harley-Davidson specialty tools and their applications.

📊 Manual Specifications

Format Details:

Searchable PDF, allowing for quick access to information via keywords.

Quality Description:

High-resolution scans ensuring clarity of text, diagrams, and illustrations.

Binding Description:

Digital (PDF format), no physical binding.

Paper Description:

Not applicable (Digital format).

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution, 45-degree V-twin

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.500 in. x 3.812 in. (88.9 mm x 96.8 mm)

Compression Ratio:

9.7:1

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder

Cooling System:

Air-cooled

Horsepower:

Approximately 65-70 HP (est. at crankshaft, actual may vary by specific tune)

Torque:

Approximately 70-75 lb-ft @ 3500 RPM (est. at crankshaft, actual may vary)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (premium)

Fuel Tank Capacity:

4.5 US gal (17.0 L)

Oil Capacity With Filter:

3.0 US qt (2.8 L)

Oil Type Specification:

Harley-Davidson Genuine Motor Oil SAE 20W50 or equivalent API SG/SH/SJ certified motorcycle oil.

🔧 Transmission

Type:

5-speed, constant mesh, sequential

Clutch:

9-plate, wet clutch

Primary Drive:

Duplex chain, 34/46 ratio (1.353:1)

Final Drive:

Belt drive, 32/66 ratio (2.063:1)

Transmission Fluid Type:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant (or equivalent SAE 85W-140 API GL-5)

Capacity:

26 oz (0.77 L)

📐 Dimensions

Length:

90.4 in. (2296 mm)

Seat Height Laden:

26.0 in. (660 mm)

Ground Clearance:

4.25 in. (108 mm)

Dry Weight:

552 lbs (250 kg)

Gross Vehicle Weight Rating Gvwr:

930 lbs (422 kg)

Front Tire:

MT90B16 72H

Rear Tire:

150/80B16 77H

Wheel Type:

Chrome, 5-spoke cast aluminum

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not subject to standardized crash test ratings like automobiles. Safety relies on rider skill and adherence to maintenance.

Braking System:

Hydraulic disc brakes, front and rear. Dual piston caliper front, single piston caliper rear.

Lighting:

Halogen headlamp, LED tail lamp and brake lamp, amber lens front and rear turn signals.

Frame Construction:

Steel, cradle frame

Ergonomics:

Forward-mounted foot controls, drag-style handlebars, solo seat for rider comfort and control.

💡 Technology Features

Audio System:

Typically no integrated audio system on the XL1200C standard model; aftermarket audio solutions are common.

Instrumentation:

Analog speedometer with integrated digital odometer and tachometer (mounted on handlebar riser). Indicator lights for turn signals, oil pressure, engine diagnostics, and neutral.

ABS Availability:

Anti-lock Braking System (ABS) was an optional feature on some 2009 Sportster models, including potentially the XL1200C. Manual should specify if ABS is equipped.

Connectivity Features:

No inherent Bluetooth or smartphone connectivity on this model; aftermarket solutions required.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1,600 km), including engine oil and filter change, primary chain adjustment, and general inspection.

Regular Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Primary Chain Check:

Check and adjust every 2,500 miles (4,000 km) or as needed.

Spark Plug Replacement:

Recommended every 10,000-15,000 miles (16,000-24,000 km).

Brake Fluid Flush:

Recommended every 2 years, regardless of mileage.

Engine Oil:

Harley-Davidson Genuine Motor Oil SAE 20W50 (or equivalent)

Primary Chaincase Lubricant:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant (or equivalent SAE 85W-140 API GL-5)

Transmission Fluid:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant (or equivalent SAE 85W-140 API GL-5)

Brake Fluid:

DOT 4 hydraulic fluid

Fork Oil:

Harley-Davidson Type E (385 cSt) or Type B (305 cSt) Fork Oil, depending on desired damping. Check manual for specifics.

Common Wear Items:

Clutch plates, brake pads, wheel bearings, steering head bearings, fork seals.

Potential Electrical Issues:

Wiring harness chafing, regulator/rectifier failure (less common on this generation but possible), battery terminal corrosion.

Engine Performance Quirks:

Vibrations inherent to the V-twin design, potential for oil leaks if seals are not maintained, carburetor tuning (on earlier models, less so on EFI) can be sensitive.

Belt Drive Maintenance:

Regular inspection for wear and proper tension is crucial to prevent premature failure.

📚 Vehicle History

Harley Davidson Legacy:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines, custom styling, and strong community.

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, evolving from basic utilitarian bikes to stylish cruisers.

Xl1200C Specifics:

The 'C' designation signifies the 'Custom' model, typically featuring more chrome, a larger front wheel, and a lower seat height for a classic cruiser look. The 1200cc Evolution engine became a staple for this model.

Production Years:

Sportster models have been in continuous production since 1957. The XL1200C variant has been a key model for many years, including 2009.

Manufacturing Base:

Primarily manufactured in the United States.

🏆 Awards & Recognition

Model Recognition:

The Sportster line, and particularly the XL1200C, has consistently been recognized for its iconic styling, V-twin performance, and its ability to be customized, making it a favorite among riders and in motorcycle media reviews over its production run.

Owner Satisfaction:

Generally high owner satisfaction for its class, often praised for its character and customization potential, despite some shared platform traits with other Sportster models.

Emissions Compliance:

Complies with EPA and CARB emissions standards for its model year.